Upright surface cleaning apparatus with offset motor

ABSTRACT

In accordance with one broad aspect of the present invention, a surface cleaning apparatus is provided. The surface cleaning apparatus comprises a surface cleaning head having a dirty fluid inlet. A fluid flow path extends from the dirty fluid inlet to a clean air outlet of the surface cleaning apparatus. An upright section is mounted to the surface cleaning head and is positioned in the fluid flow path. At least one cleaning stage is provided on the upright section. An air flow motor is provided on the upright section at least partially beside the at least one cleaning stage and in the fluid flow path.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application 60/893,982 (filed on Mar. 9, 2007), which is incorporated herein by reference in its entirety.

FIELD

This application relates to surface cleaning devices such as upright vacuum cleaners and vacuum cleaners with a handle that extends upwardly from a surface cleaning head.

BACKGROUND

Various types of surface cleaning apparatus are known in the art. Upright vacuum cleaners typically have a surface cleaning head and an upright section. The upright section includes one or more cleaning elements and is pivotally mounted to the surface cleaning head. A suction motor is provided to draw air through the cleaning element(s). The suction motor is typically positioned proximate the surface cleaning head. For example, U.S. Pat. No. 6,003,196 to Wright shows an upright vacuum cleaner in which the suction motor is in the surface cleaning head. In use, air enters the surface cleaning head, is conveyed upwards to the cleaning element, is directed back downwards towards the surface cleaning head, and passes through the suction motor and out of the air outlet.

More recently surface cleaning apparatus have been developed in which the suction motor is above the cleaning element. For example, U.S. Pat. No. 6,334,234 to Conrad shows a configuration wherein the suction motor is placed at the top of the upright section, above the cleaning element.

SUMMARY

In accordance with one broad aspect of the present invention, a surface cleaning apparatus is provided. The surface cleaning apparatus comprises a surface cleaning head having a dirty fluid inlet. A fluid flow path extends from the dirty fluid inlet to a clean air outlet of the surface cleaning apparatus. An upright section is mounted to the surface cleaning head and houses part of the fluid flow path. At least one cleaning stage is provided on the upright section. An air flow or suction motor is provided on the upright section at least partially beside the at least one cleaning stage and in the fluid flow path.

Embodiments of a surface cleaning apparatus in accordance with this broad aspect may be advantageous because, as the motor is at least partially beside the cleaning stage, the clean air exiting the cleaning stage need not be directed back downwardly towards the surface cleaning head. Accordingly, the need for additional conduits between the cleaning stage and the clean air outlet is removed, thereby reducing material costs, and reducing the overall weight of the surface cleaning apparatus.

In addition, since the air need not be directed back downwardly towards the cleaning stage, the number of bends in the fluid flow path between the cleaning stage and the clean air outlet is reduced, thereby reducing pressure losses in the surface cleaning apparatus. In particular, a bend in a conduit for a fluid causes a turbulent pressure loss in the conduit as the fluid travels through the bend in the conduit. The greater the sharpness of the bend, the greater the pressure loss. The pressure loss in the air decreases the amount of suction that can be generated at the cleaning head of the vacuum cleaner for any given motor in the vacuum cleaner and therefore the efficiency of the vacuum cleaner. Therefore, by reducing the number of bends in the fluid flow path, the amount of suction, which can be generated at the cleaning head for any given motor, is increased.

Additionally, embodiments of a surface cleaning apparatus in accordance with this broad aspect may be advantageous because the motor need not add to the overall height of the upright section. Typically, there are limits on the height of the upright section of an upright vacuum cleaner. Such limits may be determined, for example, by ergonomic factors. For example, the handle of the vacuum cleaner is preferably positioned at a height that is ergonomically acceptable to the average consumer. If the handle is positioned too far above the ground, the user may have to raise their arm upwardly above a normal operating position in order to use the vacuum cleaner. Accordingly, in vacuum cleaners wherein the motor contributes to the overall height of the upright section, the size of other components of the upright section may have to be decreased. For example, in cleaners wherein the motor is above the cleaning stage, the height of the dirt bin and/or the cyclone may have to be reduced such that the upright section can accommodate the height of the motor without the handle being positioned too high above the ground. This would reduce the overall size of the dirt bin, may reduce the efficiency of the cyclone and require that the dirt bin be emptied more frequently. In embodiments of the present invention, however, the motor does not add to the overall height of the upright section, thereby allowing the dirt bin to remain sufficiently large to minimize the need for frequent emptying.

Additionally, a surface cleaning apparatus in accordance with this broad aspect may be advantageous because the hand weight of the vacuum cleaner may be decreased as compared to vacuum cleaners in which the motor is positioned at the top of the upright section. This hand weight is based on the weight of the components that are attached to the handle that is held by the user and the distance of those units from the pivot mount of the handle. The further from the pivot (which is typically located adjacent or internal of the surface cleaning head), the greater the moment arm produced by the component and the greater the hand weight. Therefore, by positioning the motor at least partially beside the at least one cleaning stage, rather than at the top of the upright section, a reduction in hand weight is achieved.

In accordance with this broad aspect, there is provided a surface cleaning apparatus comprising:

-   -   (a) a surface cleaning head having a dirty fluid inlet;     -   (b) a fluid flow path extending from the dirty fluid inlet to a         clean air outlet of the surface cleaning apparatus;     -   (c) an upright section mounted to the surface cleaning head and         positioned in the fluid flow path;     -   (d) at least one cleaning stage provided on the upright section;         and,     -   (e) an air flow motor provided on the upright section at least         partially beside the at least one cleaning stage in the fluid         flow path.

In some embodiments, the surface cleaning apparatus further comprises an additional cleaning stage positioned in the surface cleaning head. In such an embodiment, the additional cleaning stage is preferably positioned upstream from the at least one cleaning stage provided on the upright section.

In some embodiments, the air flow motor is positioned at an upper portion of the upright section, e.g., adjacent the handle.

In some embodiments the at least one cleaning stage has a clean air outlet and the air flow motor is positioned adjacent the clean air outlet of the at least one cleaning stage. Such embodiments may be advantageous because the length of fluid flow path between the cleaning stage and the motor may be further reduced. Preferably, the air flow motor has an inlet that is at the same height as the outlet of the cleaning stage that is immediately upstream of the motor.

In some embodiments the at least one cleaning stage has a longitudinal axis and a conduit is provided between the clean air outlet of the at least one cleaning stage and the air flow motor, wherein at least a portion of the conduit extends transverse to the longitudinal axis.

In some embodiments the at least one cleaning stage comprises a cyclone.

In some embodiments the at least one cleaning stage comprises a first cleaning stage and a second cleaning stage positioned above the first cleaning stage. In a further embodiment, the air flow motor is positioned at least partially beside the second cleaning stage. In yet a further embodiment, the first cleaning stage comprises a cyclone and the second cleaning stage comprises a plurality of cyclones.

In some embodiments, the upright section comprises a backbone, and the air flow motor is mounted to the backbone. In a further embodiment, at least one cleaning stage is mounted to a front of the backbone, the air flow motor is mounted above the backbone and a handle is mounted to an air flow motor housing.

In some embodiments, the surface cleaning apparatus is selected from the group consisting of a vacuum cleaner and a carpet extractor.

In accordance with another broad aspect, an upright surface cleaning apparatus is provided. The upright surface cleaning apparatus comprises a surface cleaning head having a dirty fluid inlet. A fluid flow path extends from the dirty fluid inlet to a clean air outlet of the surface cleaning apparatus. An upright section is mounted to the cleaning head, and comprises a handle. The surface cleaning apparatus further comprises at least one cleaning stage having a fluid inlet positioned downstream from the dirty fluid inlet. The at least one cleaning stage further comprises a fluid outlet. An air flow motor is positioned downstream from the fluid outlet and is laterally spaced from the at least one cleaning stage at an upper portion of the upright section.

In some embodiments, the air flow motor is positioned at least partially beside the at least one cleaning stage.

In some embodiments, the clean air outlet is adjacent the air flow motor.

In some embodiments the surface cleaning apparatus further comprises a conduit between the fluid outlet and the air flow motor, wherein the conduit extends generally horizontally when the upright section extends vertically.

In some embodiments, the at least one cleaning stage has a longitudinal axis and a conduit is provided between the clean air outlet of the at least one cleaning stage and the air flow motor, wherein at least a portion of the conduit extends transverse to the longitudinal axis.

In some embodiments, the at least one cleaning stage comprises a cyclone.

In some embodiments, the at least one cleaning stage comprises a first cleaning stage and a second cleaning stage positioned above the first cleaning stage.

In some embodiments, the air flow motor is positioned adjacent the second cleaning stage. In a further embodiment, the air flow motor is aligned with the first cleaning stage.

In some embodiments, the first cleaning stage comprises a cyclone and the second cleaning stage comprises a plurality of cyclones.

In some embodiments, the upright section comprises a backbone, and the air flow motor is mounted to the backbone. In a further embodiment, the at least one cleaning stage is mounted to a front of the backbone, and the air flow motor is mounted above the backbone.

In some embodiments, the surface cleaning apparatus is selected from the group consisting of a vacuum cleaner and a carpet extractor.

Other aspects and features of the present specification will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:

FIG. 1 is a perspective view of an example of an upright surface cleaning apparatus according to the instant invention;

FIG. 2 is a side view of the apparatus of FIG. 1 wherein some of the components are transparent to show an optional the interior construction; and,

FIG. 3 is a top view of the apparatus of FIG. 1.

DETAILED DESCRIPTION

An embodiment of a surface cleaning apparatus 110 of the present invention is shown in FIGS. 1-3. In the embodiment shown, surface cleaning apparatus 110 is an upright vacuum cleaner. In alternate embodiments, surface cleaning apparatus 110 may be an upright carpet extractor. Alternately, surface cleaning apparatus 110 may be of any other type known in the art wherein the surface cleaning apparatus has a handle and the or an air flow motor is mounted on the handle offset from a cleaning element.

The surface cleaning apparatus 110 comprises a surface cleaning head 112 having a dirty fluid inlet 114 provided in the lower surface thereof. A fluid flow path extends from the dirty fluid inlet to a clean air outlet 124 of the surface cleaning apparatus. An upright section 116 is pivotally mounted to the surface cleaning head 112, and is in the fluid flow path. Any such construction known in the art, and any means for mounting an upright section or handle to a surface cleaning head may be used.

The upright section 116 comprises at least one cleaning stage, which removes particulate matter from fluid passing through the fluid path. As exemplified in FIG. 2, upright section 116 preferably comprises first and second cleaning stages 120 and 122, respectively downstream of and in fluid communication with the dirt inlet 114 and upstream of and in fluid communication clean air outlet 124 of the apparatus 110. It will be appreciated that one or more cleaning elements or components may be positioned in a surface cleaning head 112.

In the example illustrated, the upright section 116 comprises a backbone 117 of, e.g., structural tubular material. The backbone 117 comprises a fluid flow passage extending upwardly from the cleaning head 112, and providing fluid communication between the dirt inlet 114 and the first cleaning stage 120. Backbone 117 may be a rigid conduit (e.g. a plastic or metal pipe) or may comprise a flexible hose associated with a rigid member surrounding part or all of the flexible hose. In other embodiments, upright section may comprise a housing having a recess in which one or more cleaning stage 120, 122 is removably mounted and a handle 174 may be formed as part of the upright section.

The apparatus 110 further comprises an air flow motor 130 for generating an air stream from the dirt inlet 114 to the clean air outlet 124. In the example illustrated, the air flow motor 130 is housed in a motor housing 168. The motor 130 is laterally spaced from, or at least positioned partially beside, at least one of the cleaning stages 120, 122. In the example illustrated, the motor 130 is laterally spaced from the second cleaning stage 122, and the motor housing 168 is mounted to the upper end of the backbone 117 at an upper portion 132 of the upright section 116, such that the motor 130 is above the backbone 117. As exemplified, it is preferred that motor 130 is axially aligned with cleaning stage 120.

It will be appreciated that backbone 117 need not terminate at motor 130. As exemplified, motor 130 is mounted on the top of backbone 117. Motor housing 168 may therefore define a platform from which handle 174 extends. Accordingly, motor housing 168 may provide the mount for handle 174 or may have handle 174 formed as part thereof.

In the exemplified embodiment, motor 130 is positioned rearwardly of second cleaning stage 122. In other embodiments, motor 130 may be otherwise positioned with respect to second cleaning stage 122, for example forwardly of second cleaning stage 122.

Alternately, or in additional as shown in the exemplified embodiment, motor 130 is beside second cleaning stage 122. In alternate embodiments, motor 130 may be only partially beside second cleaning stage 122. For example, motor 130 may be laterally spaced from second cleaning stage 122, as well as longitudinally shifted with respect to second cleaning stage 122, such that a portion of motor 130 is above or below second cleaning stage 122.

In the embodiment shown, motor 130 is beside second cleaning stage 122, and accordingly is positioned on an upper portion of the upright section 116. In other embodiments (not shown), motor 130 may be positioned at least partially beside, or laterally spaced from first cleaning stage 120. In such embodiments, motor 130 may be positioned on a lower portion of the upright section 116. In a further alternate embodiment, motor 130 may be positioned partially beside both of first cleaning stage 120 and second cleaning stage 122. That is, motor 130 may be positioned such that a top portion of motor 130 is beside second cleaning stage 122, and a bottom portion of motor 130 is beside first cleaning stage 120.

In the embodiment of FIG. 2, the treated air exiting second stage 122 is redirected 90° and then travels generally linearly to the inlet of the motor housing. Accordingly, it will be appreciated that it is preferred for the housing 168 for the motor 130 to be positioned adjacent the clean air outlet of the cleaning stage, such that the inlet to the motor housing 168 is at the same height as the clean air outlet from the cleaning stage immediately upstream of the motor 130. Such a configuration reduces the number of bends and, in particular, the number of 90° bends. It will be appreciated that the conduit may extend linearly at an angle to the clean air outlet of the immediately upstream cleaning stage.

In some embodiments, at least one of the cleaning stages 120, 122 may comprise a cyclone 136, and at least one of the cleaning stages 120, 122 may comprise a plurality of cyclones 136 in parallel. In the example illustrated, the first cleaning stage 120 comprises a single first stage cyclone 138, which is oriented generally along a first axis 140.

The first cyclone 138 is, in the example illustrated, mounted to the backbone 117 by a hollow connector 142. The hollow connector 142 comprises a portion of the fluid flow passage between the dirt inlet 114 and the first cleaning stage 120. It will be appreciated that connector 142 need not be hollow and need not comprise a portion of the fluid flow path through the apparatus.

The first cleaning stage 120 further includes an optional dirt collection chamber 144 that is preferably positioned below the first cyclone 138. The first cyclone 138 may be housed in a first housing 146, portions or all of which may comprise the wall defining the cyclone chamber of first cyclone 138 (i.e., first cyclone 138 may be the first housing 146). The dirt collection chamber may be removably mounted, such as to the first housing 146 or to the first cyclone 138.

The second cleaning stage 122 is mounted downstream of the first cleaning stage 120. Second cleaning stage 122 may be any cleaning stage known in the surface cleaning arts and preferably comprises a cyclonic cleaning stage. In the example illustrated, the second cleaning stage 122 comprises a plurality of second stage cyclones 152 connected in parallel, that are preferably mounted together in a cylindrical assembly (also referred to as a multi-cyclone assembly) 154 having a second axis 156 (i.e., they are removable as a unit). The plurality of second stage cyclones have an inlet that receives fluid discharged from the first cleaning stage 120, and has a clean air outlet that discharges fluid towards the air flow motor 130.

The plurality of second stage cyclones 152 may have at least one second stage dirt collection chamber associated therewith, and preferably a plurality of second stage dirt collection chambers. The plurality of second stage cyclones 152 may be housed in a second housing 162, and the at least one second dirt collection chamber may be removably mounted to the second housing 162, with or without second stage cyclones 152. The multi-cyclone assembly 154 and the second dirt collection chamber or chambers may be removably mounted to the apparatus 110 as a closed unit. Once the closed unit is removed from the apparatus 110, the second dirt collection chamber or chambers may be opened for evacuating dirt collected therein.

It is preferred that the inlet to the second stage is proximate the outlet from the first stage and, more preferably, that that the inlet to the second stage is adjacent and, most preferably, linearly aligned with, the outlet from the first stage. Accordingly, the first and second cleaning stages 120, 122 are, in the example illustrated, positioned coaxially. The first axis 140 of the first cleaning stage 120 is in-line with the second axis 156 of the second cleaning stage 122. The first and second cleaning stages 120, 122 are preferably positioned forwardly of the backbone 117.

The first cleaning stage 120 has a top 164 and the second cleaning stage 122 is preferably positioned on the top 164 of the first cleaning stage 120. The second cleaning stage 122 may also be secured to the backbone 117 by, for example, a web 166 positioned at a lower end thereof. It will be appreciated that first and second cleaning stages 120, 122 may each be removably mounted to backbone 177 and may be separately removably mounted or removably mounted as a unit. Accordingly, second cleaning stage 122 need not be directly mounted to backbone 117 by a web 166.

In the example illustrated, the air flow motor 130 has a motor axis 170 that is parallel with, and spaced laterally apart from, the second axis 156 of the second cleaning stage 122. The motor 130 is, in the example illustrated, in axial registration with the second cleaning stage 122. A flow conduit 172 extends laterally between a clean air outlet at an upper end of the second housing 162 and the motor housing 168 to provide fluid communication therebetween. Preferably, as illustrated, conduit 172 is generally horizontal, and transverse to the second axis 156.

In some embodiments, the motor housing 168 and the second housing 162 may adjoin and share a wall in common.

The apparatus 110 may further comprise a handle 174 to facilitate maneuvering the apparatus 110 over a surface to be cleaned. The handle 174 may extend upwardly from the motor housing 168. Alternately, it will be appreciated that handle 174 may be attached to backbone 117 and may be part of backbone 117. In such an embodiment, motor housing 168 may be mounted to backbone 117 by any means known in the art. It will be appreciated that backbone 117 may include the handle of the surface cleaning apparatus.

In other examples, only some of the first and second cleaning stages and the fluid flow motor are mounted to the backbone, and those of the first and second cleaning stages and the air flow motor which are not mounted thereto are mounted to at least one of the first and second cleaning stages and the fluid flow motor.

It will be appreciated that each cleaning stage may be of any design known in the art. Preferably, the cleaning stage or stages on the upright section comprise at least one cyclone and may be of any design known in the art. It will be appreciated that one or more cleaning stages may be provided in the surface cleaning head and are preferably upstream of the cleaning stage or stages on the upright section. The cleaning stage or stages in the surface cleaning head preferably comprise at least one cyclone.

While the above description provides examples of one or more processes or apparatuses, it will be appreciated that other processes or apparatuses may be within the scope of the accompanying claims. 

1. A surface cleaning apparatus comprising: a) a surface cleaning head having a dirty fluid inlet; b) a fluid flow path extending from the dirty fluid inlet to a clean air outlet of the surface cleaning apparatus; c) an upright section mounted to the surface cleaning head and positioned in the fluid flow path; d) at least one cleaning stage provided on the upright section; and, e) an air flow motor provided on the upright section at least partially beside the at least one cleaning stage in the fluid flow path.
 2. The surface cleaning apparatus of claim 1, further comprising an additional cleaning stage positioned in the surface cleaning head.
 3. The surface cleaning apparatus of claim 2, wherein the additional cleaning stage is positioned upstream from the at least one cleaning stage provided on the upright section.
 4. The surface cleaning apparatus of claim 1, wherein the airflow motor is positioned at an upper portion of the upright section.
 5. The surface cleaning apparatus of claim 1, wherein the at least one cleaning stage has a clean air outlet and the airflow motor is positioned adjacent the clean air outlet of the at least one cleaning stage.
 6. The surface cleaning apparatus of claim 1, wherein the at least one cleaning stage has a longitudinal axis and a conduit is provided between the clean air outlet of the at least one cleaning stage and the air flow motor, wherein at least a portion of the conduit extends transverse to the longitudinal axis.
 7. The surface cleaning apparatus of claim 1, wherein the at least one cleaning stage comprises a cyclone.
 8. The surface cleaning apparatus of claim 1, wherein the at least one cleaning stage comprises a first cleaning stage and a second cleaning stage positioned above the first cleaning stage.
 9. The surface cleaning apparatus of claim 8, wherein the airflow motor is positioned at least partially beside the second cleaning stage.
 10. The surface cleaning apparatus of claim 9, wherein the first cleaning stage comprises a cyclone and the second cleaning stage comprises a plurality of cyclones.
 11. The surface cleaning apparatus of claim 1, wherein the upright section comprises a backbone, and the airflow motor is mounted to the backbone.
 12. The surface cleaning apparatus of claim 11, wherein the at least one cleaning stage is mounted to a front of the backbone, the airflow motor is mounted above the backbone and a handle is mounted to an airflow motor housing.
 13. The surface cleaning apparatus of claim 1, wherein the surface cleaning apparatus is selected from the group consisting of a vacuum cleaner and a carpet extractor.
 14. An upright surface cleaning apparatus comprising: a) a surface cleaning head having a dirty fluid inlet; b) a fluid flow path extending from the dirty fluid inlet to a clean air outlet of the surface cleaning apparatus; c) an upright section mounted to the cleaning head, the upright section comprising a handle; d) at least one cleaning stage having a fluid inlet positioned downstream from the dirty fluid inlet and a fluid outlet; and, e) an airflow motor positioned downstream from the fluid outlet and laterally spaced from the at least one cleaning stage at an upper portion of the upright section.
 15. The upright surface cleaning apparatus of claim 14, wherein the airflow motor is positioned at least partially beside the at least one cleaning stage.
 16. The upright surface cleaning apparatus of claim 14, wherein the clean air outlet is adjacent the airflow motor.
 17. The upright surface cleaning apparatus of claim 14, further comprising a conduit between the fluid outlet and the airflow motor, wherein the conduit extends generally horizontally when the upright section extends vertically.
 18. The upright surface cleaning apparatus of claim 14, wherein the at least one cleaning stage has a longitudinal axis and a conduit is provided between the clean air outlet of the at least one cleaning stage and the airflow motor, wherein at least a portion of the conduit extends transverse to the longitudinal axis.
 19. The upright surface cleaning apparatus of claim 14, wherein the at least one cleaning stage comprises a cyclone.
 20. The upright surface cleaning apparatus of claim 14 wherein the at least one cleaning stage comprises a first cleaning stage and a second cleaning stage positioned above the first cleaning stage.
 21. The upright surface cleaning apparatus of claim 20, wherein the airflow motor is positioned adjacent the second cleaning stage.
 22. The upright surface cleaning apparatus of claim 20, wherein the airflow motor is aligned with the first cleaning stage.
 23. The upright surface cleaning apparatus of claim 21, wherein the first cleaning stage comprises a cyclone and the second cleaning stage comprises a plurality of cyclones.
 24. The upright surface cleaning apparatus of claim 14, wherein the upright section comprises a backbone, and the airflow motor is mounted to the backbone.
 25. The upright surface cleaning apparatus of claim 23, wherein the at least one cleaning stage is mounted to a front of the backbone, and the airflow motor is mounted above the backbone.
 26. The upright surface cleaning apparatus of claim 14, wherein the surface cleaning apparatus is selected from the group consisting of a vacuum cleaner and a carpet extractor.
 27. The upright surface cleaning apparatus of claim 14, further comprising an additional cleaning stage positioned in the surface cleaning head.
 28. The upright surface cleaning apparatus of claim 27, wherein the additional cleaning stage is positioned upstream from the at least one cleaning stage. 